On-Pallet Dual-Belt Mechanism Driven by Off-Pallet Motor for Cable Handling at Processing Module

Abstract

A system for processing a cable end of a cable. The system includes: a pallet delivery system; a cable processing module; a pallet supported by the pallet delivery system; an on-pallet dual-belt cable feed mechanism configured for linear feeding of the cable end into the cable processing module; and an off-pallet electric motor operatively coupled for driving circulation of a pair of belts of the dual-belt cable feed mechanism. The cable processing module includes cable processing equipment configured to perform an operation on the cable end and a computer. The computer is configured to: (a) cause the dual belts to circulate in respective cable pushing directions to cause a specified length of cable to be inserted into the cable processing equipment; (b) activate the cable processing equipment to perform an operation on the inserted end of the cable; and (c) cause the dual belts to circulate in respective cable pulling directions to cause the specified length of cable to be withdrawn from the cable processing equipment.

1 . An apparatus for feeding a cable into cable processing equipment, the apparatus comprising a pallet configured to carry the cable and a dual-belt cable feed mechanism mounted to the pallet, wherein the dual-belt cable feed mechanism comprises:
 first through fourth pulleys which are rotatable relative to the pallet;   a drive gear which is rotatable in tandem with the first pulley along a first common axis of rotation, wherein the drive gear comprises a multiplicity of teeth;   an idler gear which is rotatable in tandem with the third pulley along a second common axis of rotation, wherein the idler gear comprises a multiplicity of teeth and some of the teeth of the idler gear are meshed with some of the teeth of the drive gear;   a first belt that passes around the first and second pulleys; and   a second belt that passes around the third and fourth pulleys,   wherein the first and second belts are arranged to contact opposing sides of a portion of the cable disposed therebetween; and   wherein the first and second belts circulate concurrently and in opposite directions during rotation of the drive gear.   
     
     
         2 . The apparatus as recited in  claim 1 , further comprising a first shaft assembly that is rotatably coupled to the pallet and comprises a head, wherein the drive gear and the first pulley are fixedly mounted to the first shaft assembly. 
     
     
         3 . The apparatus as recited in  claim 2 , further comprising a second shaft assembly that is rotatably coupled to the pallet, wherein the idler gear and the third pulley are fixedly mounted to the second shaft assembly. 
     
     
         4 . The apparatus as recited in  claim 3 , wherein the first shaft assembly further comprises an input shaft, a first gear shaft, and a first pulley shaft fixedly coupled in series, the apparatus further comprising a second pulley shaft, wherein:
 the head projects from an end of the first shaft;   the drive gear is fixedly mounted to the first gear shaft;   the first pulley is fixedly mounted to the first pulley shaft; and   the second pulley is fixedly mounted to the second pulley shaft.   
     
     
         5 . The apparatus as recited in  claim 4 , wherein the second shaft assembly comprises a second gear shaft and a third pulley shaft fixedly coupled to the second gear shaft, the apparatus further comprising a fourth pulley shaft, wherein:
 the idler gear is fixedly mounted to the second gear shaft;   the third pulley is fixedly mounted to the third pulley shaft; and   the fourth pulley is fixedly mounted to the fourth pulley shaft.   
     
     
         6 . The apparatus as recited in  claim 1 , wherein:
 each of the first through fourth pulleys has a respective multiplicity of teeth along a respective outer periphery thereof;   each of the first and second belts has a respective multiplicity of teeth molded on an inner surface thereof;   some of the teeth of the first belt are meshed with some of the teeth of the first pulley, while other teeth of the first belt are meshed with some of the teeth of the second pulley; and   some of the teeth of the second belt are meshed with some of the teeth of the third pulley, while other teeth of the second belt are meshed with some of the teeth of the fourth pulley.   
     
     
         7 . The apparatus as recited in  claim 2 , wherein the head comprises a solid body having at least one rectangular planar side surface. 
     
     
         8 . The apparatus as recited in  claim 2 , wherein the head comprises a solid body having at least one trapezoidal planar side surface. 
     
     
         9 . The apparatus as recited in  claim 2 , wherein the head comprises a solid body having splines. 
     
     
         10 . The apparatus as recited in  claim 1 , wherein the first and second belts are made of compliant material. 
     
     
         11 . The apparatus as recited in  claim 1 , wherein:
 the pallet comprises a corral that defines a recess;   the corral comprises a circular wall having a discontinuity and first and second planar walls extending from the discontinuity; and   the first and second belts are disposed side-by-side in a portion of the recess between the first and second planar walls.   
     
     
         12 . A system comprising a nut driver apparatus installed at a workstation and a cable feeding apparatus positioned adjacent to the workstation,
 wherein the nut driver apparatus comprises:   a bearing assembly comprising a guide which is oriented vertically and a carriage which is translatably coupled to the guide;   a linear actuator comprising an elongated machine element coupled to the carriage;   an arm having one end affixed to the carriage;   an electric motor mounted to the arm and comprising a motor output shaft;   a drive shaft fixedly coupled to the motor output shaft; and   a socket fixedly coupled to an end of the drive shaft, and   wherein the cable feeding apparatus comprises:   a pallet configured to carry wound cable; and   a dual-belt cable feed mechanism mounted to the pallet, wherein the dual-belt cable feed mechanism comprises:
 an input shaft which is rotatable relative to the pallet about a first axis of rotation and comprises a head which is configured to interlock with the socket when the drive shaft is aligned with and in contact with the input shaft; and 
 first and second belts ( 86   a ,  86   b ) which circulate concurrently in opposite directions when the input shaft is rotated. 
   
     
     
         13 . The system as recited in  claim 12 , wherein the socket is not interlocked with the head when the carriage is at a first elevation and is interlocked with the head when the carriage is at a second elevation below the first elevation. 
     
     
         14 . The system as recited in  claim 12 , wherein the elongated machine element comprises a lead screw, the linear actuator further comprising a nut that is attached to the carriage and threadably coupled to the lead screw. 
     
     
         15 . The system as recited in  claim 12 , wherein the elongated machine element comprises a rack, the linear actuator further comprising a pinion gear which is rotatable relative to the guide. 
     
     
         16 . The system as recited in  claim 12 , wherein the linear actuator is a pneumatic actuator and the elongated machine element comprises a piston rod which is linearly displaceable and has an end fixedly coupled to the carriage. 
     
     
         17 . The system as recited in  claim 12 , further comprising:
 a motor controller which is configured to control operation of the electric motor in response to commands; and   a computer which is configured to output commands to the motor controller to control operation of the electric motor.   
     
     
         18 . The system as recited in  claim 17 , wherein the computer is further configured to activate the linear actuator to lower the drive shaft by a distance sufficient to interlock the head with the socket and then issue commands to the motor controller that controls the electric motor to drive rotation of the drive shaft while the socket is interlocked with the head, thereby causing the input shaft to rotate and the first and second belts to circulate. 
     
     
         19 . The system as recited in  claim 18 , wherein the computer is further configured to issue commands to the motor controller that control the electric motor to drive rotation of the drive shaft by a number of degrees calculated to cause the first and second belts to feed a predetermined length of cable disposed between and contacted by the first and second belts. 
     
     
         20 . The system as recited in  claim 12 , wherein the dual-belt cable feed mechanism further comprises:
 first through fourth pulleys which are rotatable relative to the pallet;   a drive gear which is rotatable in tandem with the first pulley about the first axis of rotation, wherein the drive gear comprises a multiplicity of teeth;   an idler gear which is rotatable in tandem with the third pulley about a second axis of rotation, wherein the idler gear comprises a multiplicity of teeth and some of the teeth of the idler gear are meshed with some of the teeth of the drive gear;   a first belt that passes around the first and second pulleys; and   a second belt that passes around the third and fourth pulleys.   
     
     
         21 . A method for processing a cable end of a cable, the method comprising:
 (a) placing a coil of cable on a pallet that supports a dual-belt cable feed mechanism comprising an input shaft which is rotatable relative to the pallet and first and second belts which circulate concurrently in opposite directions when the input shaft is rotated, wherein the input shaft comprises a head which is configured to interlock with a socket which is fixedly coupled to an end of a drive shaft;   (b) placing the end of the cable between the first and second belts;   (c) moving the pallet to a cable feed position whereat the input shaft is aligned with the socket;   (d) activating a linear actuator to displace the drive shaft downward until the socket engages the head of the input shaft; and   (e) activating an electric motor to drive rotation of the drive shaft in a first direction while the socket is engaged with the head, thereby causing the first and second belts to push the cable forward into cable processing equipment,   wherein steps (d) and (e) are performed under control by a computer.   
     
     
         22 . The method as recited in  claim 21 , further comprising:
 (f) activating the cable processing equipment to perform a cable processing operation on the end of the cable; and   (g) activating the electric motor to drive rotation of the drive shaft in a second direction opposite to the first direction while the socket is engaged with the head, thereby causing the belts to pull the cable out of the cable processing equipment,   wherein steps (f) and (g) are performed under control by the computer.